Implementation of design for environment principles in product development using a case study on the design of a passenger car door

Abstract

Product design is a complex process that requires design engineers taking into consideration а number of factors simultaneously. Though the primary aim is to fulfil a given function in a cost effective manner, in recent years considerable emphasis has been placed on designing products that result in minimal negative environmental impact. In the past, research has focussed on developing tools that assist designers in selecting suitable materials and manufacturing processes in the early stages of product design itself. A correct choice of materials can have a significant impact on promoting Design for Environment (DfE) and determining suitable End of Life (EoL) strategies such as recycling, reuse and remanufacture. This dissertation highlights the importance of implementing design aspects such as Design for Assembly (DfA) and Design for Disassembly (DfD). Included is a case study which illustrates the benefits of implementing DfD in the design of a passenger car door. Through a prudent selection of suitable materials, manufacturing processes and also joining and dismantling techniques, the overall sustainability of the product can been increased. It is seen that in order to incorporate DfE principles in product design, the designers must deal with vast amounts of data simultaneously. Dealing with such large quantities of data can be tricky. This dissertation proposes arranging materials, manufacturing processes and assembly and disassembly techniques in the form of an ontology so that designers can have access to design information in a systematic and precise format. The principles to construct a DfE tool that assists design engineers not only select suitable materials, manufacturing processes and assembly/disassembly methods, but also helps analyse every stage of the product’s life and measure its impact on the environment during the initial stages of design itself have been provided in this dissertation.